Method and apparatus for forming underwater structures



April 18, 1967 G. A. BARON ETAL 3,314,239

METHOD AND APPARATUS FOR FORMING UNDERWATER STRUCTURES Filed Feb. 17, 1964 5 Sheets-Sheet l INVENTOR GUY A. BARON I c/Efl/V 5 R/VE Hg 4 AND/Q [676 400 9mm gm ATTORNEXfi April 1967 G. A. BARON ETAL 3,314,239

METHOD AND APPARATUS FOR FORMING UNDERWATER STRUCTURES Filed Feb. 17, 1964 5 Sheets-Sheet 2 INVENTORS GUY BARON dEA/V BER/YE AND/Q5 G/RAUD ATTORNEYS April 1967 G. A. BARON ETAL 3,314,239

METHOD AND APPARATUS FOR FORMING UNDERWATER STRUCTURES Filed Feb. 17, 1964 5 Sheets-Sheet 5 /V B J) l I K I Figs NJ :3: F INVENTORS T euy BARON dEAN BERNE ANDRE G/RAUD ATTORNEYS April 18, 1967 v G. A. BARON ETAL 3,314,239

METHOD AND APPARATUS FOR FORMING UNDERWATER STRUCTURES Filed Feb. 17, 1964 5 Sheets$heet 4 ATTORNEY6 April 18, 1967 BARON ETAL 3,314,239

METHOD AND APPARATUS FOR FORMING UNDERWATER STRUCTURES Filed Feb. 17, 1964 5 Sheets-Sheet 5 FIG. 7

INVENTORS GUY BARON JEA V BERNE BY ANDRE G/RAUD Wm m {6% ATTORNEYS FIG. 8

United States Patent 3,314,239 METHOD AND APPARATUS FOR FORMING UNDERWATER STRUCTURES Guy A. Baron, Colombes, Jean Berne, Vernouillet, Seineet-(Bise, and Andi- Y. Giraud, Paris, France, assignors to Institut Francais du Petrole, des Carburants & Lubrifiants, Rueil-Malmaison, Seine-et-Oise, France Filed Feb. 17, 1964, Ser. No. 345,422

Claims priority, application France, Feb. 21, 1963,

925,629, Patent 1,417,990; Sept. 27, 1963, 948,994,

Patent 86,308

7 Claims. (CI. 6146) The present invention relates to a method of producing solid masses on the bottom of the sea and apparatus for performing the same.

The lowering of heavy masses to the bottom of the sea poses a number of difficult problems. For example, such operations have to be carried out from a ship or a floating platform subjected to the action of the waves. For this reason, the place from which the lowering of heavy masses is conducted undergoes considerable variations in the level of location. In the open sea, these variations can amount to several meters. The assembly of the heavy mass and the cable from which it is suspended form an elastic system, the constants of which vary with the length of the cable. It is obvious that the resonance conditions in the cable resulting from the upper level fluctuations can lead to overtensioning and breaking of the cable.

Accordingly, it is an object of the present invention to provide apparatus on a ship or floating platform which is particularly adapted to withstand the forces which are much higher than the static forces resulting from the weight of the mass and the cable.

Another object of this invention is to provide apparatus for the casting of heavy masses and the like on the bottom of the sea, which apparatus makes it possible to feed casting substance to the bottom of the sea and is at the same time relatively light so as not to require a large ship or floating platform to be operated from.

Another object of this invention is to provide a method by means of which various objects and heavy masses can be produced on the bottom of the sea regardless of its depth, this method being free of the disadvantages which are normally encountered by lowering masses through the water to the bottom of the sea.

, Still another object of the present invention is to provitle a method for making various structures on the bottom of the sea by using a flexible envelope of relatively weak resistance holding frames therein, said frames having been put in previously, and which correspond to the form of the desired structure.

The method, according to the present invention, consists in feeding, by means of a delivery pump, a liquid or mixture of liquid and solids, (hereinafter called mortar, through a flexible pipe leading from a ship or the like to the bottom of the sea. pumped into a bag or form solidifies in the shape of the filled bag or form after a suitable delay. Said bag or form is attached to the lower end of the pipe. Once filled and completely solidified, a solid mass or other structure has been formed right on the bottom of the sea.

In order to allow the construction of concrete masses in the sea, suitable frames can be provided in the bag or form before lowering the same to the bottom of the sea. In conncetion with the frame means, a fastening ring can be provided which projects from the solid mass. This ring can be used to remove or displace a solid mass.

The bag used for receiving the mortar can be made of a flexible material like plastic or rubberized canvas. The form can be made of rigid materials such as metal or wood.

This mortar which is It stands to reason that low-cost material is used for making the bags to hold the mortar. Any such material, however, must be adaptable so as to assume any required shape of the desired finished article. At any rate, the flexible material must have sufficient mechanical strength to be able to stand the pressure differential between the internal pressure due to the height and weight of the liquid and solidified mixture in the bag and the external hydrostatic pressure being exerted thereon.

Among the structures which can be constructed on the bottom of the sea, there are, for example, platforms which are raised relative to the ground, well heads, concrete pillars and other structures associated with such pillars.

In order to produce structures of the type described, the process according to the invention employs a number of separate filling stages, thereby expanding the bag which may contain suitable frames.

The use of separate filling stages is of particular importance when the submarine structures are rather long, vertically. The quantity of mortar introduced in each stage is chosen in such a manner that the difference between the interior pressure corresponding to the weight of the mortar in the bag and the hydrostatic pressure is lower than the pressure differential limit which the bag can stand.

In this manner, the risk of a broken bag is avoided. When the amount of mortar for one filling stage has been fed into the bag, it is first allowed to solidify before the amount of motar for the next following filling stage is put in. Thus, various structures of any height can be constructed on the bottom of the sea without the need of a bag which has great mechanical resistance.

Other advantages of the invention will be apparent from the following description in conjunction with the accompanying drawings, in which like references refer to like parts throughout the several figures, and wherein:

FIG. 1 is a wide view of the basic elements constituting the present invention;

FIG. 2 is a view of a flexible, empty or partly inflated bag containing frame means therein and (in dashed lines) of said bag with frame means after it has been filled with mortar;

FIGS. 3, 3A and 4 show different types of forms used for casting solid masses;

FIG. 4A shows a safety valve of a known type suitable for evacuation of water and mortar in excess from the container or form;

- FIGS. 5 and 5A show devices for disconnecting the mortar feeding tube from the bag or form after filling thereof;

FIGS. 6, 6A, 7 and 8 show examples of various submarine structures which can be constructed according to the method and apparatus of the present invention.

When referring to the drawings more in detail and turning first to FIG. 1, it is shown how a mortar is fed from a ship N by a pump P through a flexible pipe T. A pump of the type used for drilling With relatively low power output is sufiicient since gravity is utilized for aiding the descent of the mortar in the pipe T. The pipe T is of the type used for drilling. It is flexible and reinforced by suitable means e.g. metal threads.

The pipe T may have an inner diameter of about mm., and its resistance is chosen in accordance with the density of the mixture which it is to hold. The pipe portions used at greater depth which have to resist greater interior pressure due to the weight of the mortar column, can advantageously be chosen of stronger pipe material than employed for the pipes near the surface.

As shown in FIG. 2, the pipe T carries at its lower end a container (bag or form) C. The bag can be made of flexible material such as plastic, and the form can be made of material such as wood or metal. Since neither the bag nor the form ha to withstand too much pressure but is merely intended to hold the mortar prior to solidification, low-cost materials and constructions can be used.

When a flexible bag is used, the air can be preliminarily removed therefrom so as to reduce its volume. Inside said bag frame means A are disposed which may be of metal. When a heavy, solid mass is to be constructed, it is advisable to attach a fastening ring to the frame means A which projects through the bag. The bag, which is fixed to the mortar feeding pipe, can be lowered to the bottom of the sea without difiiculties.

when little by little, the mortar fills the bag, the latter keeps expanding until it reaches its maximum extension. The mortar solidifies in due course after having surrounded the frame means and assumed the shape of the bag upon extension. A safety valve may be provided at the upper end of the bag to allow any surplus mortar to escape.

The form, as shown in FIGS 3 and 3A, has a horizontal plate B which is used as a cover. Its dimension corre spond roughly to the inside dimensions of the form C, leaving some play between the two elements. The plate B can slide inside the form C along the pipe T fixed to the form and opening into the lower part of the form. When the form C is lowered into the water, the cover B is in its lower-most position, just above the output opening F of the pipe T. In this way, the form C is filled with water, the pressures being equal on either side of the walls. It can therefore be easily lowered. Upon feeding mortar through the pipe T, thereby filling the form, little by little, the Cover B which lies all the time on the surface of the mortar, rises toward the upper portion of the form until it reaches the same upon a complete filling of the form. Thereby, contact between mortar and water i avoided at all times. As a frame member, a metallic rod M may be provided in the form C. To the end of this rod M, there is attached a ring 0. The rod M may either be placed inside or outside of the pipe T.

FIG. 3A illustrates the case where the rod M serving partly as a frame member is placed outside of the pipe T.

In FIG. 3, where the rod M is inside the pipe T, the rods diameter is chosen so as to be much smaller than the interior diameter of the pipe T so that an annular passage is left therebetween through which the mortar can flow. The rod M is at least as high as the form C and carries a ring 0 at its upper end, the diameter of which is, of course, smaller than the inner diameter of the pipe T. The rod M which stands inside the pipe T (FIG. 3) is solidly fixed with its lower end I to the plate, which constitutes the bottom of the form C. When the form is completely filled with mortar and the plate B has reached its upper position, the pipe T is detached from the form C in a manner which will be described later. The mortar solidifies around the rod M. Thereafter, the ring is the only part thereof which is positioned outside of the form C.

FIG. 4 illustrates another embodiment of the form C. Instead of a rod, a metallic folding structure A is provided. This structure slides with its lower arms in a sliding rail G1 and with its upper arms in a sliding rail G2. The sliding rail G1 is located in the base of the form, whereas the sliding rail G2 is provided in the cover B. The metallic rod portions which make up the metallic folding structure A are interconnected by pivots so as to allow it to unfold while the cover B rises progressively with the rising mortar. In the embodiment shown in FIG. 4, the rod M projects through the cover B which has an aperture H for that purpose. A fastening ring 0 is provided at the Upper end of the rod M. The cover B has an orifice Q for the introduction of mortar. A safety valve of a known type will be provided on the cover B, such ,as the valve V of FIGURE 4A,

having a cap N which is lifted by water or mortar in excess in the form C when the latter is filled through the flexible pipe T, allowing said water or mortar to escape through a slot or aperture W.

In all the above described embodiments (FIGS. 3A, 3, 4), the fastening ring 0 at the outside of the bag or form C is in connection with the ship by means of a cable (FIG. 1) which is not pulled taut until the mortar has solidified. In order that the ship be allowed to move during the time it takes for the mortar to solidify, the cable V can be attached to a floating object like a buoy.

When the bag or form has been filled, but prior to solidification of the mortar, the flexible pipe T is detached from the bag or form C to allow the lifting upward of the pipe while the heavy mass or cast structure remains on the bottom of the sea.

The flexible pipe T can 'be attached to the bag or form C by means of a sleeve K (FIGS. 3, 3A, 5 and 5A). The sleeve K is fixed to the bag or form C and kept tightly connected to the mouthpiece E of the pipe T (FIGS. 5, 5A). A completely watertight interconnection between the mouthpiece E and the pipe T can be ensured by suitable annular means like tightening rings J.

The mouthpiece E of the pipe T can be kept firmly attached to the sleeve K by a shearing cotter-pin G (FIG. 5A) which resists the shearing force corresponding to the weight of the container (bag or form) including any frame members, but cannot resist a shearing force which is substantially larger than the ordinary shearing force resulting from the weight of the container.

When the filling operation of the bag or form C has been completed, the pipe T can be easily detached from the sleeve K by exerting a traction force upon the pipe T. Thereby, a shearing of the cotter-pin G is attained.

The detachment of the pipe T from the sleeve K can also be carried out by an arrangement, as shown in FIG. 5. According to this device, the cotter-pin G traverses the sleeve K and is held with one of its ends in a cavity D arranged in the mouthpiece E, and its other end is associated with a spring R1 which urges the cotter-pin G out of its position. However, the pin is kept in its engaged position by the arm of a lever L which in turn is blocked by a second lever arm S which holds the system in engaged position by a spring R2. Disenga'gement of this blocking system is caused by simply dropping a collar U of suflicient mass to compress the spring R2 on impact. The collar U surrounds the pipe T loosely. When the spring R2 is compressed, the outer end of the lever arm S frees the arm of lever L and causes the disengagement of the spring R1, thereby releasing the cotter-pin G.

The method, according to the present invention, makes it possible to carry out rapidly and economically the construction of heavy masses or other submarine structures, right on the bottom of the sea. The operation can be carried out with natural or delayed solidification of a casting mass at the temperature surrounding the apparatus.

It is also possible to use elevated temperatures by providing suitable electric heating means which are fed from the ship through wires incorporated in the pipes. These electrical heating means can be used to maintain a higher surrounding temperature for the duration of solidification of the mortar.

FIG. 6 shows in a perspective view a Well head formed in a bag of flexible material which is, for example, filled by three conduits forming the terminal portion of a common pipe means.

FIG. 6A illustrates a sectional view of a difie-rent form of a well head constructed by filling a bag which contains a frame.

FIG. 7 shows a concrete pillar in section. It has been formed by means of a flexible bag stretched around four longitudinal frame rods.

FIG. 8 shows an elevated platofrm, also constructed by pouring mortar into aflexible bag stretched around four longitudinal frame rods.

FIG. 8 shows an elevated platform, also constructed by pouring mortar into a flexible bag.

All these different structures may be formed by pouring mortar in different successive stages. Complete solidification of the mortar introduced at one stage has to occur before the next casting stage is initiated, whereby the quantity of mixture introduced at each stage is such that the difference between the maximum interior pressure due to the weight of the mixture height in the bag and the hydrostatic pressure is lower than the pressure differential limit which the bag can withstand.

It will be understood that this invention is susceptible to modification in order to adapt it to different usages and conditions and, accordingly, it is desired to comprehend such modification within this invention as may fall within the scope of the appended claims.

What is claimed as this invention is:

1. Apparatus for the construction of structures of predetermined shape on the bottom of a body of water from an installation positioned at the surface thereof, comprising a container to be lowered from said installation to the bottom of said body of water, a pump on said installation, flexible pipe means connecting said pump to said container, said pump being adapted for feeding a mixture of liquid and solids capable of solidifying to said container through said flexible pipe means, said container comprising a substantially rigid form, a container bottom secured to said rigid form, a movable cover slidably mounted in said rigid form, said flexible pipe means having a feed outlet opening through said cover, said cover being provided with a safety valve and being displaceable in said rigid form from a collapsed position to an expanded position by feeding said container with said mixture of liquid and solids, said expanded position corresponding to said predetermined shape of the structure.

2. Apparatus according to claim 1, further comprising a frame element in the form of a rod, said rod having a first end fixed to the container bottom, an opening in said movable cover providing a passage for said rod, said cover being movable along said rod and a fastening ring attached to the second end of said rod.

3. Apparatus according to claim 1, comprising a flexible pipe, an opening in said movable cover for said flexible pipe, said apparatus further comprising a rod, said rod being fixed to the bottom of said container and disposed inside said flexible pipe.

4. Apparatus for the construction of structures on the bottom of a body of water from an installation positioned at the surface thereof, comprising a container to be lowered from said installation to the bottom of said body of water, a pump on said installation, flexible pipe means connecting said pump to said container, said pump being adapted for feeding a mixture of liquid and solids capable of solidifying to said container through said flexible pipe, sleeve means being provided in said container for connection thereof with each of said flexible pipe means, each of said flexible pipe means having a mouthpiece adapted to be inserted into a corresponding sleeve and provided with a cavity, a cotter pin traversing said sleeve and entering said cavity, lever means pivotally mounted on the outside of said sleeve for cooperation with said cotter pin, first spring means urging said cotter pin outside said cavity against said lever means, second spring means acting on said lever means so as to engage said cotter pin into said cavity, heavy collar means adapted to be dropped to said container from said installation at the surface along said flexible pipe, said sec-0nd spring means being adapted to release, on impact of said collar means, their action on said lever means, thereby releasing said cotter pin.

5. A method for constructing structures of predetermined shape on the bottom of a body of water from an installation positioned at the surface thereof, comprising the steps of lowering to the bottom from said surface installation a container comprising a substantially rigid form, a container bottom secured to said rigid form, a movable cover provided with a safety valve and slidably mounted in said rigid form and displaceable therein from a collapsed position to an expanded position correspond ing to the predetermined shape of the structure, said container being connected to said surface installation through flexible pipe means and an opening through said cover to fill progressively said container from said surface installation through said flexible pipe means with a mixture of liquid and solids capable of solidifying, thereby causing expansion of said movable cover, allowing said mixture to solidify, and then detaching the pipe means from said container.

6. A method according to claim 5, wherein said pipe means are secured to said container by resilient connection means and said pipe means are detached from said container after solidification of said mixture of liquid and solids by dropping heavy collar means on said resilient connection means from said surface installation.

7. A method according to claim 5, wherein said pipe means are secured to said container through a shearing attachment and said pipe means are detached from said container after solidification of said mixture of liquid and solids by exerting a suflicient traction force on said flexible pipe means.

References Cited by the Examiner UNITED STATES PATENTS Re. 25,614 7/1964 Turzillo 6135 961,492 6/1910 Goldsborough 61-53.6 1,115,490 11/1914 Bindley et a1 62646 X 1,421,857 7/1922 Store 6146 2,771,747 11/1956 Rechtin 61-465 3,091,089 5/1963 Gelerstad 61-46 FOREIGN PATENTS 33,675 1912 Sweden.

OTHER REFERENCES Hirth, German printed application No. 1,135,381, 1962.

CHARLES E. OCONNELL, Primary Examiner. JACOB SHAPIRO, Assistant Examiner. 

5. A METOD FOR CONSTRUCTING STRUCTURES OF PREDETERMINED SHAPE ON THE BOTTOM OF A BODY OF WATER FROM AN INSTALLATION POSITIONED AT THE SURFACE THEREOF, COMPRISING THE STEPS OF LOWERING TO THE BOTTOM FROM SAID SURFACE INSTALLATION A CONTAINER COMPRISING A SUBSTANTIALLY RIGID FORM, A CONTAINER BOTTOM SECURED TO SAID RIGID FORM, A MOVABLE COVER PROVIDED WITH A SAFETY VALVE AND SLIDABLY MOUNTED IN SAID RIGID FORM AND DISPLACEABLE THEREIN FROM A COLLAPSED POSITION TO AN EXPANDED POSITION CORRESPONDING TO THE PREDETERMINED SHAPE OF THE STRUCTURE, SAID CONTAINER BEING CONNECTED TO SAID SURFACE INSTALLATION THROUGH FLEXIBLE PIPE MEANS AND AN OPENING THROUGH SAID COVER TO FILL PROGRESSIVELY SAID CONTAINER FROM SAID SURFACE INSTALLATION THROUGH SAID FLEXIBLE PIPE MEANS WITH A MIXTURE OF LIQUID AND SOLIDS CAPABLE OF SOLIDIFYING, THEREBY CAUSING EXPANSION OF SAID MOVABLE COVER, ALLOWING SAID MIXTURE TO SOLIDIFY, AND THEN DETACHING THE PIPE MEANS FROM SAID CONTAINER. 